Forming equipment for rolling and profiling disk-shaped and ring-shaped parts

ABSTRACT

The invention relates to forming equipment for rolling and profiling disk-shaped and ring-shaped parts of a metallic material, e.g., of steel, of super alloys, aluminum alloys, etc., whereby a pressure rolling device without its own axial drive designed as a transportable and replaceable construction unit that it can be replaceably mounted in a conventional forging press between a press ram and the press bed plate for axial rolling. Because of this, the investment costs for otherwise conventional pressure rolling machines is reduced considerably and current forging presses can be used without remodeling for axial rolling by integrating a pressure rolling device according to the invention.

[0001] The invention relates to forming equipment for rolling and profiling of disk-shaped and ring-shaped parts.

[0002] Producing ring-shaped workpieces with highly profiled cross sections like welding neck flanges or the like in a pressure rolling machine is known from DE 26 11 568 A1. Because of the slant of the upper die with respect to the lower die at an acute angle, only a relatively low pressing force is necessary, whereby parts can be formed with very precise contours. Because of the necessary special foundations, pressure rolling machines also require considerable investments.

[0003] Forging presses, e.g., for high temperature forging of ring-shaped or disk-shaped parts are also known, which require considerable investments.

[0004] The invention is based on the task of improving a forming device of the type described, in that the advantages of forging and pressure rolling can be combined without having their disadvantages. In particular, the investment costs required by conventional pressure rolling machines will be considerably reduced and the investments for press forging will be used more efficiently.

[0005] The task is solved by the characteristics given in Patent claim 1.

[0006] The forming equipment according to the invention combines the advantages of a pressure rolling device and those of a forging press, without taking on their disadvantages. The pressure rolling device is a self-contained unit that is used in an available forging press and e.g., forms disk-shaped or ring-shaped parts of metallic materials, especially of steel. In this process, the pressure rolling machine is not mechanically connected with the forging press, rather it only obtains rolling pressure in the axial direction from the forging press. Thus, this means that the pressure rolling equipment does not have any drive of its own for application of the axial rolling force. Because of the angle of inclination of the upper die of the pressure rolling equipment of about 3 to 15 degrees, only a fraction of the otherwise usual pressing force for forge pressing is necessary to produce the required forming work. In this way, forming can be carried out with relatively low pressing force on parts in desired dimensions, i.e., with precise contours. This not only has the advantage that a great deal of material can be saved but because of the precise contour rolling, the fiber orientation will not be interrupted during metal cutting. This means that the mechanical properties of the forged parts are significantly better. However, a special advantage exists in that the necessary separate foundations and setups that are otherwise necessary with conventional pressure rolling machines can be avoided since the pressure rolling equipment is integrated according to the invention as a replaceable construction unit in the forging press so that because of an appropriate die quick change system, there can be a changeover from one workpiece type to the other in a relatively short time.

[0007] It is also of special advantage, that a pressure rolling device according to the invention can be used in forging presses that are already available. Because of this, available forging presses can also be utilized in a better way than would otherwise be possible. On the other hand, because of the lower investment costs for a pressure rolling device according to the invention—in contrast to pressure rolling machines with their own axial drive for applying the pressing force and their own foundation—lower investment costs are necessary accordingly for manufacturing of the pressure rolling device. The upper and lower die units of the pressure rolling device have electrical or hydraulic and/or electrohydraulic drives. In order to absorb the horizontal forces during rolling, corresponding guides can be provided but these are not connected to the actual forging press since the pressure rolling device is placed only on the press bed plate. The return force of the device acts continuously against the press ram. The upper and lower bearing unit has roller bearings and has recirculating oil lubrication. In the center of the lower bearing unit, an ejector can be provided that lifts the rolled part after forming so that a manipulator can take it.

[0008] As regards the dies for the pressure rolling device, these can be mounted optionally with screws or with a quick connect system. With one device, it is also possible to have the upper die lay on the lower die. Both dies can then be lifted by the ejector and can then be taken out by the manipulator.

[0009] All the energy connections for electrical, hydraulic, cooling, lubrication and control can be designed as quick connects or plug connectors so that a very fast connection to the appropriate energy supplies is possible without errors. However, an uncoupling is also equally fast if the pressure rolling device will be taken out of the forging press. After the independent control of the device is switched on, rolling can begin. Only linking signals are exchanged between the press control and the control for the pressure rolling device, whereby suitable electric and/or electronic components of a conventional type are used. If the device is removed from the press, completely normal production can take place again with the forging press.

[0010] In a preferred embodiment, according to Patent claim 2 the press bed plate can be moved in the horizontal plane and holds the pressure rolling device, whereby an upper housing of the pressure rolling device is guided mechanically so that it can be adjusted with respect to the lower housing of same and connected to it. Because of this, by using a shop crane or the like, the pressure rolling device that is designed as a construction unit can be placed on the press bed plate that has been run out and can be run under the press ram and after that the energy supply lines can be connected using quick connectors in order to bring the forming device into a position appropriate for function. During removal of the pressure rolling machine, the procedure is reversed. This means that after loosening and/or interrupting the energy supplies, the press bed plate is run out and the pressure rolling device is removed from it.

[0011] It is especially effective if, according to Patent claim 3, the mechanical connection to the lower housing of the pressure rolling device is produced using several, preferably four, guide pillars that are connected to the upper housing of the pressure rolling device and that are guided with a gliding movement in the corresponding recesses of the lower housing. The connection of the guide columns to the upper housing of the pressure rolling device can be carried out e.g., by contraction, but also in another suitable manner.

[0012] Patent claim 4 describes a preferred embodiment of the invention.

[0013] Further advantageous embodiments are described in Patent claims 5 and 6.

[0014] The invention is shown—in part schematically—in the drawings. They show:

[0015]FIG. 1 A vertical cross section through a forming device according to the invention, partially in side view, partially cut away;

[0016]FIG. 2 A top view of FIG. 1, also shown cut-away and

[0017]FIG. 3 A side view of FIG. 1, partially in cross section, whereby the pressure rolling device is shown with the press bed plate driven laterally out of the forging press.

[0018] Reference character 1 indicates a press that is only schematically shown which has the conventional design and can be set up according to the operating conditions. Since the overall structure of forging press 1 is not significant for explaining the function method, only parts of forging press 1 will be indicated.

[0019] Reference character 2 shows the hydraulically driven press ram. The hydraulic drive for press ram 2 was not specially marked.

[0020] In 3, a press bed plate 3 that can be moved in a horizontal direction and also can be run out of press 1 and run into press 1 is shown. The movement capability in a horizontal direction of this press bed plate 3 is schematically indicated by a double arrow in FIG. 1.

[0021] Reference character 4 indicates column guides, of which a total of four units are shown, which are arranged distributed uniformly in the corner areas of a square or rectangle (FIG. 2) and can be guided with a sliding movement in the corresponding pocket holes of a lower machine housing 5, whereby bearing seals are mounted in each area of the upper opening of pocket holes for guide columns 4 which also seal the column guide to the outside against dirt and moisture. The lower machine housing 5 holds a lower forming die 6 of a pressure rolling device that has the appropriate contour of the workpiece to be rolled. The lower forming die 6 is mounted in the lower machine housing 5 so that it can be changed, whereby axially-spaced roller bearings 7 hold the lower rolling unit, consisting of the lower forming die 6 and a bearing part 15.

[0022] In 8, a lower die drive is indicated that can have a design that is conventional for pressure rolling machines such as an electric motor, a hydraulic motor, or a gear motor.

[0023] As can be seen from FIG. 1, an upper forming die 9 is also provided that is tilted with its forming contour at an acute angle to the lower forming die 6 of e.g., 3 to 15 and that is mounted in an upper machine housing 10 so that it can be replaced.

[0024] In 11, axially-spaced roller bearings are provided for holding the upper roller unit, consisting of the upper forming die 9 and an upper bearing part 16. The upper rolling unit is driven by an upper die drive 12, which can also have the conventional design used in pressure rolling machines.

[0025] Press bed plate 3 of hydraulic press 1 is mounted on a lower press cross head 13 so that it can be moved with transverse movements, if necessary using bearings that are not shown.

[0026] A lifting device is indicated with 14, which can be, e.g., a load hook that is to be coupled with a crane hook that is only indicated schematically and by which the construction unit consisting of lower machine housing 5, column guides 4, lower bearing part 15, lower forming die 6, upper machine housing 10, upper bearing part 16 with upper forming die 9 and all the drives and an ejector 17 that can be motor-driven are lifted together off of press bed plate 3 and/or placed on it. This means that it is easy to replace the entire pressure rolling device, whereupon after press bed plate 3 is run back into press 1, in its usual position it can be operated in its usual manner, while when pressure rolling device is mounted in the press, the axial rolling force can be applied by press ram 2 and as a reaction force by press bed plate 3 can be applied to the forming dies 6 and 9.

[0027] As can be seen, in this way a separate foundation or frame for the pressure rolling device can be eliminated, so when needed the pressure rolling device can be integrated in the forging press. The quick connects for producing the energy supplies for the pressure rolling device drives are not shown for reasons of simplification. Also for reasons of simplification the control means and the control lines that are used to move the pressure rolling device on one hand, and to coordinate it to the press 1 on the other, are not shown.

[0028] The operating method of the forming device that can be seen in the drawing is as follows:

[0029] The pressure device that is to be handled overall as a construction unit is placed by means of a shop crane or the like on press bed plate 3 (FIG. 3) that has been run out. The upper machine housing 10 is mechanically connected for this purpose to the lower machine housing 5 by way of column guides 4 and a mechanical safety device between the upper (10) and lower machine housing (5). The column guides 4 are connected to the upper machine housing 10 by contraction or the like so that they are fixed, but replaceable.

[0030] After that, press bed plate 3 is run into the press center of press 1. After that, all the energy connections are plugged in and/or connected, i.e., for electrical, hydraulic, cooling and lubrication. After the equipment's own control is switched on, rolling can be started. Linking signals are exchanged between the press control on one side and the pressure rolling device on the other side. When the pressure rolling device is removed from hydraulic press 1, production can continue as usual with press 1.

[0031] The characteristics described in the summary, in the patent claims and in the description, as well as those that can be seen in the drawing, can be present both individually as well as in any combinations for implementing the invention.

SUMMARY

[0032] The invention relates to forming equipment for rolling and profiling disk-shaped and ring-shaped parts of a metallic material, e.g., of steel, of super alloys, aluminum alloys, etc., whereby a pressure rolling device without its own axial drive designed as a transportable and replaceable construction unit that it can be replaceably mounted in a conventional forging press between a press ram and the press bed plate for axial rolling. Because of this, the investment costs for otherwise conventional pressure rolling machines is reduced considerably and current forging presses can be used without remodeling for axial rolling by integrating a pressure rolling device according to the invention. 

1. Forming equipment for rolling and profiling disk-shaped and ring-shaped parts wherein a pressure rolling device (4, 5, 6, 7, 8, 9, 10, 11, 12) without its own axial rolling drive is mounted, as a transportable and replaceable construction unit, in a conventional forging press (1) between a press ram (2) and a press bed plate (3), whereby the press (1) applies the axial rolling force.
 2. Forming equipment according to claim 1, characterized in that the press bed plate (3) can be moved in horizontal direction and holds the pressure rolling equipment (4, 5, 6, 7, 8, 9, 10, 11, 12) and that an upper machine housing (10) of the pressure rolling equipment (4, 5, 6, 7, 8, 9, 10, 11, 12) is guided mechanically so that it can be adjusted and is connected with a lower machine housing (5) of same.
 3. Forming equipment according to claim 2, characterized in that the mechanical connection is produced with several, preferably four, column guides (4) with return traverse, which are tightly connected to the upper machine housing (10) of the pressure rolling equipment (4, 5, 6, 7, 8, 9, 10, 11, 12) and that are guided in corresponding recesses of the lower machine housing (5) so that they can move by sliding.
 4. Forming equipment according to claim 1 or one of the following claims, characterized in that all the energy supply lines for the pressure rolling equipment (4, 5, 6, 7, 8, 9, 10, 11, 12) for electrical energy, hydraulic energy, for cooling and lubrication, as well as for control are connected with quick connects, especially with plug connectors.
 5. Forming equipment according to claim 1 or one of the following claims, characterized in that the pressure rolling equipment (4, 5, 6, 7, 8, 9, 10, 11, 12) has its own control and hydraulics and is only linked to press (1) by signals in such a way that press (1) is fully functional without integration of the pressure rolling equipment (4, 5, 6, 7, 8, 9, 10, 11, 12).
 6. Forming equipment according to claim 1 or one of the following claims, characterized in that depending on the workpiece temperature measured in the rolling slot, the feed of the press ram (2) can be controlled in such a way that the forming temperature is constant or nearly constant over the entire rolling process, especially for high-temperature-resistant materials, e.g., steel alloys, super alloys and/or aluminum alloys. 